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Evaluation of all-electric secondary power for transport aircraft

This report covers a study by Douglas Aircraft Company (DAC) of electrical power systems for advanced transport aircraft based upon an all-electric design concept. The concept would eliminate distributed hydraulic and pneumatic secondary power systems, and feature an expanded secondary electrical power system redesigned to supply power to the loads customarily supplied by hydraulic or pneumatic power. The initial study was based on an advanced 20-kHz electrical power transmission and distribution system, using a system architecture supplied by NASA-Lewis Research Center for twin-engine aircraft with many advanced power conversion concepts. NASA-LeRC later requested DAC to refocus the study on 400-Hz secondary power distribution. Subsequent work was based on a three-engine MD-11 aircraft, selected by DAC as a baseline system design that would provide data for the comparative cost/benefit analysis. The study concluded that the 20-kHz concept produced many expected benefits, and that the all-electric trijet weight savings on hardware redesign would be 2,304 pounds plus a 2.1-percent fuel reduction and resized for a total weight reduction of 11,000 pounds. Cost reductions for a fleet of 800 aircraft in a 15-year production program were estimated at $76.71 million for RDT&E; $2.74 million per aircrat for production; $9.84 million for nonrecurring expenses; $120,000 per aircraft for product support; and $300,000 per aircraft per year for operating and maintenance costs, giving a present value of $1.914 billion saved or a future value of $10.496 billion saved.

Murray, W. E.↗

Ammonia Leak Locator Study

The thermal control system of International Space Station Alpha will use liquid ammonia as the heat exchange fluid. It is expected that small leaks (of the order perhaps of one pound of ammonia per day) may develop in the lines transporting the ammonia to the various facilities as well as in the heat exchange equipment. Such leaks must be detected and located before the supply of ammonia becomes critically low. For that reason, NASA-JSC has a program underway to evaluate instruments that can detect and locate ultra-small concentrations of ammonia in a high vacuum environment. To be useful, the instrument must be portable and small enough that an astronaut can easily handle it during extravehicular activity. An additional complication in the design of the instrument is that the environment immediately surrounding ISSA will contain small concentrations of many other gases from venting of onboard experiments as well as from other kinds of leaks. These other vapors include water, cabin air, CO2, CO, argon, N2, and ethylene glycol. Altogether, this local environment might have a pressure of the order of 10(exp -7) to 10(exp -6) torr. Southwest Research Institute (SwRI) was contracted by NASA-JSC to provide support to NASA-JSC and its prime contractors in evaluating ammonia-location instruments and to make a preliminary trade study of the advantages and limitations of potential instruments. The present effort builds upon an earlier SwRI study to evaluate ammonia leak detection instruments [Jolly and Deffenbaugh]. The objectives of the present effort include: (1) Estimate the characteristics of representative ammonia leaks; (2) Evaluate the baseline instrument in the light of the estimated ammonia leak characteristics; (3) Propose alternative instrument concepts; and (4) Conduct a trade study of the proposed alternative concepts and recommend promising instruments. The baseline leak-location instrument selected by NASA-JSC was an ion gauge.

Dodge, Franklin T.↗

Spatial Orientation and Balance Control Changes Induced by Altered Gravito-Inertial Force Vectors

Seventeen healthy and eight vestibular deficient subjects were exposed to an interaural centripetal acceleration of 1 G (resultant 45 deg roll tilt of 1.4 G) on a 0.8 meter radius centrifuge for a period of 90 minutes in the dark. The subjects sat with head fixed upright, except every 4 of 10 minutes when instructed to rotate their head so that their nose and eyes pointed towards a visual point switched on every 3 to 5 seconds at random places (within +/- 30 deg) in the Earth horizontal plane. Motion sickness caused some subjects to limit their head movements during significant portions of the 90 minute period, and led three normal subjects to stop the test earlier. Eye movements, including directed saccades for subjective Earth- and head-referenced planes, were recorded before, during, and immediately after centrifugation using electro-oculography. Postural stability measurements were made before and within ten minutes after centrifugation. In normal subjects, postural sway and multisegment body kinematics were gathered during an eyes-closed head movement cadence (sway-referenced support platform), and in response to translational/rotational platform perturbations. A significant increase in postural sway, segmental motion amplitude and hip frequency was observed after centrifugation. This effect was short-lived, with a recovery time of several postural test trials. There were also asymmetries in the direction of post-centrifugation center of sway and head tilt which depended on the subject's orientation during the centrifugation adaptation period (left ear or right ear out). To delineate the effect of the magnitude of the gravito-inertial vector versus its direction during the adaptive centrifugation period, we tilted eight normal subjects in the roll axis at a 45 deg angle in the dark for 90 minutes without rotational motion. Their postural responses did not change following the period of tilt. Based on verbal reports, normal subjects overestimated roll-tilt during 90 minutes of both tilt and centrifugation stimuli. Subjective estimates of head-horizontal, provided by directed saccades, revealed significant errors after approximately 30 minutes that tended to increase only in the group who underwent centrifugation. Immediately after centrifugation, subjects reported feeling tilted on average 10 degrees in the opposite direction, which was in agreement with the direction of their earth-directed saccades. In vestibular deficient (VD) subjects, postural sway was measured using a sway-referenced or earth-fixed support surface, and with or without a head movement sequence. 'Me protocol was selected for each patient during baseline testing, and corresponded to the most challenging condition in which the patient was able to maintain balance with eyes closed. Bilaterally VD subjects showed no postural decrement after centrifugation, while unilateral VD subjects had varying degrees of decrement. Unilateral VD subjects were tested twice; they underwent centrifugation both with right ear out and left ear out. Their post-centrifuation center of sway shifted at right angles depending on the centrifuge GIF orientation. Bilateral VD subjects bad shifts as well, but no consistent directional trend. VD subjects underestimated roll-tilt during centrifugation, These results suggest that orientation of the gravito-inertial vector and its magnitude arc both used by the central nervous system for calibration of multiple orientation systems. A change in the background gravito-inertial force (otolith input) can rapidly initiate postural and perceptual adaptation in several sensorimotor systems, independent of a structured visual surround.

Kaufman, Galen D.↗

Accomplishments of the Advanced Reusable Technologies (ART) RBCC Project at NASA/Marshall Space Flight Center

The focus of the NASA / Marshall Space Flight Center (MSFC) Advanced Reusable Technologies (ART) project is to advance and develop Rocket-Based Combined-Cycle (RBCC) technologies. The ART project began in 1996 as part of the Advanced Space Transportation Program (ASTP). The project is composed of several activities including RBCC engine ground testing, tool development, vehicle / mission studies, and component testing / development. The major contractors involved in the ART project are Aerojet and Rocketdyne. A large database of RBCC ground test data was generated for the air-augmented rocket (AAR), ramjet, scramjet, and ascent rocket modes of operation for both the Aerojet and Rocketdyne concepts. Transition between consecutive modes was also demonstrated as well as trajectory simulation. The Rocketdyne freejet tests were conducted at GASL in the Flight Acceleration Simulation Test (FAST) facility. During a single test, the FAST facility is capable of simulating both the enthalpy and aerodynamic conditions over a range of Mach numbers in a flight trajectory. Aerojet performed freejet testing in the Pebble Bed facility at GASL as well as direct-connect testing at GASL. Aerojet also performed sea-level static (SLS) testing at the Aerojet A-Zone facility in Sacramento, CA. Several flight-type flowpath components were developed under the ART project. Aerojet designed and fabricated ceramic scramjet injectors. The structural design of the injectors will be tested in a simulated scramjet environment where thermal effects and performance will be assessed. Rocketdyne will be replacing the cooled combustor in the A5 rig with a flight-weight combustor that is near completion. Aerojet's formed duct panel is currently being fabricated and will be tested in the SLS rig in Aerojet's A-Zone facility. Aerojet has already successfully tested a cooled cowl panel in the same facility. In addition to MSFC, other NASA centers have contributed to the ART project as well. Inlet testing and parametrics were performed at NASA / Glenn Research Center (GRC) and NASA / Langley Research Center (LaRC) for both the Aerojet and Rocketdyne concepts. LaRC conducted an Air-Breathing Launch Vehicle (ABLV) study for several vehicle concepts with RBCC propulsion systems. LaRC is also performing a CFD analysis of the ramjet mode for both flowpaths based on GASL test conditions. A study was performed in 1999 to investigate the feasibility of performing an RBCC flight test on the NASA / Dryden Flight Research Center (DFRC) SR-71 aircraft. Academia involvement in the ART project includes parametric RBCC flowpath testing by Pennsylvania State University (PSU). In addition to thrust and wall static pressure measurements, PSU is also using laser diagnostics to analyze the flowfield in the test rig. MSFC is performing CFD analysis of the PSU rig at select test conditions for model baseline and validation. Also, Georgia Institute of Technology (GT) conducted a vision vehicle study using the Aerojet RBCC concept. Overall, the ART project has been very successful in advancing RBCC technology. Along the way, several major milestones were achieved and "firsts" accomplished. For example, under the ART project, the first dynamic trajectory simulation testing was performed and the Rocketdyne engine A5 logged over one hour of accumulated test time. The next logical step is to develop and demonstrate a flight-weight RBCC engine system.

Nelson, Karl W.↗

Airships for Planetary Exploration

The feasibility of utilizing an airship for planetary atmospheric exploration was assessed. The environmental conditions of the planets and moons within our solar system were evaluated to determine their applicability for airship flight. A station-keeping mission of 50 days in length was used as the baseline mission. Airship sizing was performed utilizing both solar power and isotope power to meet the baseline mission goal at the selected planetary location. The results show that an isotope-powered airship is feasible within the lower atmosphere of Venus and Saturn s moon Titan.

Colozza, Anthony↗

Time Variable Gravity from Local Mascon Analysis of GRACE Data

We have analyzed GRACE Level 1-B data in 2003 and assessed a new approach for extracting time variable gravity that isolates the gravity signal in both time and space. The Level-1B satellite-to-satellite range rate (KBRR) data and accelerometry are processed in daily arcs using the precise orbit products produced by the GRACE team from GPS to calibrate both the accelerometer and KBRR data. We then adjusted select components of the intersatellite baseline vector for each data segment isolated to the region of interest. Herein, we solved for mass anomalies in 45 deg x 45 deg blocks over the Amazon and the nearby Atlantic Ocean and estimate mass flux in units of cm of water over each block. We show with this approach that we can recover mass anomalies on a submonthly basis with 10 to 15 day temporal resolution. We discuss the important issues related to this solution, including the size of the mascon blocks, the weight given to the temporal and spatial constraint used to stabalize the solutions, as well as the optimal correlation in time and distance. We compare the the mascon results with solutions obtained from the more standard approach using spherical harmonics and with independent hydrology models and lake data. This technique demonstrates that sub-monthly medium wavelength mass flux phenomena are well sensed by the hyper-precise line of sight velocity data produced from GRACE.

Lemoine, Frank G.↗

Technology Plan for the Terrestrial Planet Finder Interferometer

The technology plan for the Terrestrial Planet Finder Interferometer (TPF-I) describes the breadth of technology development currently envisaged to enable TPF-I to search for habitable worlds around nearby stars. TPF-I is currently in Pre-Phase A (the Advanced Study Phase) of its development. For planning purposes, it is expected to enter into Phase A in 2010 and be launched sometime before 2020. TPF-I is being developed concurrently with the Terrestrial Planet Finder Coronagraph (TPF-C), whose launch is anticipated in 201 6. The missions are being designed with the capability to detect Earth-like planets should they exist in the habitable zones of Sun-like (F,G, and K) stars out to a distance of about 60 light-years. Each mission will have the starlight-suppression and spectroscopic capability to enable the characterization of extrasolar planetary atmospheres, identifying biomarkers and signs of life. TPF-C is designed as a visible-light coronagraph; TPF-I is designed as a mid-infrared formation-flying interferometer. The two missions, working together, promise to yield unambiguous detections and characterizations of Earth-like planets. The challenges of planet detections with mid-infrared formation-flying interferometry are described within this technology plan. The approach to developing the technology is described through roadmaps that lead from our current state of the art through the different phases of mission development to launch. Technology metrics and milestones are given to measure progress. The emphasis of the plan is development and acquisition of technology during pre-Phase A to establish feasibility of the mission to enter Phase A sometime around 2010. Plans beyond 2010 are outlined. The plan contains descriptions of the development of new component technology as well as testbeds that demonstrate the viability of new techniques and technology required for the mission. Starlight-suppression (nulling) and formation-flying technology are highlighted. Although the techniques are described herein, the descriptions are only at a high-level, and tutorial material is not included. The reader is expected to have some familiarity with the principles of long-baseline mid-infrared interferometry. Selected references to existing literature are given where relevant.

Lawson, Peter R.↗

Aerobraking Cost and Risk Decisions

Four missions have successfully employed aerobraking at Venus and Mars to reduce the spacecraft orbit period and achieve the desired orbit geometry. The propellant mass reductions enabled by the aerobraking technique allow the use of smaller launch systems, which translate to significant savings in launch costs for flight projects. However, there is a significant increase in mission risk associated with the use of aerobraking. Flying a spacecraft through a planetary atmosphere hundreds of times during months of around-the-clock operations places the spacecraft in harm's way, and is extraordinarily demanding on the flight team. There is a cost/risk trade that must be evaluated when a project is choosing between a mission baseline that includes aerobraking, or selecting a larger launch vehicle to enable purely propulsive orbit insertion. This paper provides a brief history of past and future aerobraking missions, describes the aerobraking technique, summarizes the costs associated with aerobraking, and concludes with a suggested methodology for evaluating the cost/risk trade when considering the aerobraking approach.

risk analysis↗

Structures and Mechanisms Design Concepts for Adaptive Deployable Entry Placement Technology

System studies have shown that large deployable aerodynamic decelerators such as the Adaptive Deployable Entry and Placement Technology (ADEPT) concept can revolutionize future robotic and human exploration missions involving atmospheric entry, descent and landing by significantly reducing the maximum heating rate, total heat load, and deceleration loads experienced by the spacecraft during entry [1-3]. ADEPT and the Hypersonic Inflatable Aerodynamic Decelerator (HIAD) [4] share the approach of stowing the entry system in the shroud of the launch vehicle and deploying it to a much larger diameter prior to entry. The ADEPT concept provides a low ballistic coefficient for planetary entry by employing an umbrella-like deployable structure consisting of ribs, struts and a fabric cover that form an aerodynamic decelerator capable of undergoing hypersonic flight. The ADEPT "skin" is a 3-D woven carbon cloth that serves as a thermal protection system (TPS) and as a structural surface that transfers aerodynamic forces to the underlying ribs [5]. This paper focuses on design activities associated with integrating ADEPT components (cloth, ribs, struts and mechanisms) into a system that can function across all configurations and environments of a typical mission concept: stowed during launch, in-space deployment, entry, descent, parachute deployment and separation from the landing payload. The baseline structures and mechanisms were selected via trade studies conducted during the summer and fall of 2012. They are now being incorporated into the design of a ground test article (GTA) that will be fabricated in 2013. It will be used to evaluate retention of the stowed configuration in a launch environment, mechanism operation for release, deployment and locking, and static strength of the deployed decelerator. Of particular interest are the carbon cloth interfaces, underlying hot structure, (Advanced Carbon- Carbon ribs) and other structural components (nose cap, struts, and main body) designed to withstand the pressure and extremely high heating experienced during planetary entry.

Yount, Bryan C.↗

Electrostatic Discharge Testing of Carbon Composite Solar Array Panels for Use in the Jovian Environment

NASA is currently considering a mission to investigate the moons of Jupiter. When designing a spacecraft for this type of mission, there are a number of engineering challenges, especially if the mission chooses to utilize solar arrays to provide the spacecraft power. In order for solar arrays to be feasible for the mission, their total mass needed to fit within the total budget for the mission, which strongly suggested the use of carbon composite facesheets on an aluminum core for the panel structure. While these composite structures are a good functional substitution for the metallic materials they replace, they present unique challenges when interacting with the harsh Jovian space environment. As a composite material, they are composed of more than one material and can show different base properties depending in differing conditions. Looking at the electrical properties, in an Earth-based environment the carbon component of the composite dominates the response of the material to external stimulus. Under these conditions, the structures strongly resembles a conductor. In the Jovian environment, with temperatures reaching 50K and under the bombardment from energetic electrons, the non-conducting pre-preg binding materials may come to the forefront and change the perceived response. Before selecting solar arrays as the baseline power source for a mission to Jupiter, the response of the carbon composites to energetic electrons while held at cryogenic temperatures needed to be determined. A series of tests were devised to exam the response of a sample solar array panel composed of an M55J carbon weave layup with an RS-3 pre-preg binder. Test coupons were fabricated and exposed to electrons ranging from 10 keV to 100 keV, at 1 nA/cm2, while being held at cryogenic temperatures. While under electron bombardment, electrical discharges were observed and recorded with the majority of discharges occurring with electron energies of 25 keV. A decrease in temperature to liquid nitrogen temperatures showed a marked increase in the magnitude of these discharges. The results indicate that dielectric discharges are primarily produced due to the presence of large regions of the non-conductive pre-preg on the surface of the carbon sheets. The frequency and magnitude of discharges decreased when layers of the pre-preg material were removed from the composite surface. These tests indicate that solar array panels may be used in the Jovian environment, but that electrostatic discharges can be expected on the carbon composite solar arrays.

Jupiter↗

Electrostatic Discharge Testing of Carbon Composite Solar Array Panels for NASA's Planned Europa Mission to Jupiter

The next planned NASA mission to visit Jupiter is known as the Europa Mission. The objective of this mission concept is to enter orbit around Jupiter in order to conduct multiple close flybys of the icy moon Europa. After careful trade studies, the mission designers have selected solar arrays as the baseline power system for the proposed mission rather than more traditional radioisotope thermoelectric generators. In order to examine the risk of using solar arrays, a series of tests were devised to determine the response of a typical solar array coupon to energetic electrons. Test coupons were fabricated and exposed to electrons ranging from 10 keV to 100 keV, at 1 nA/cm2, while being held at both room and cryogenic temperatures and exposed to end of mission radiation levels. While under electron bombardment, electrical discharges were observed and recorded with the majority of discharges occurring with electron energies of 25 keV. The largest effects on discharge size and rate were the decrease in temperature and the reduction of dielectric material on the sample surface. These tests indicate that solar array panels could be used by the planned Europa Mission in the Jovian environment, but that electrostatic discharges could be expected on the carbon composite solar arrays.

carbon composite↗

A Reynolds-Averaged Navier-Stokes Perspective for the High Lift Common Research Model Using the LAVA Framework

An in-depth assessment of the High Lift-Common Research Model (HL-CRM) aerodynamic performance is made using a Reynolds-Averaged Navier-Stokes (RANS) methodology. Results presented here were produced in support of the 4th AIAA High Lift Prediction Workshop(HLPW-4), with additional simulation results and analysis used to support findings from the workshop. Mesh resolution, RANS closure models, and tunnel effects were among the sources of simulation sensitivity addressed, all in the pursuit of evaluating best-practice simulation methods for complex high-lift configurations. In general, free-air simulations using RANS yield accurate predictions of integrated loads in the pre-stall regime for the HL-CRM, while strong sensitivity to simulation method is observed near CLmax. Additionally, a study assessing changes in aerodynamic performance due to flap deflection angle indicated strong sensitivity to turbulence model closure and mesh resolution, particularly at the highest deflection setting. Several available corrections for the Spalart-Allmaras (SA) turbulence model were tested and generally introduced more error relative to the experiment in comparison to the baseline SA closure model. The Standard Menter Baseline Two-Equation (k-ωBSL) turbulence model was also explored, which arguably yielded results highly consistent with experiment, but at a substantially higher computational cost. Therefore, as a compromise between computational cost and accuracy, the baseline SA closure model was selected for additional HL-CRM studies that assess alternative solution methods. These strategies include “warm start” approaches, which initialize the simulation from a previously converged solution at a nearby angle of attack, unsteady calculations, and simulations that model the experimental wind tunnel. Results from these studies would reinforce the shortcomings of RANS in predicting aircraft performance at high-lift conditions, namely at high-αand highly loaded flap conditions, while also answering questions about appropriate modeling techniques to minimize the errors associated with RANS where possible

TTT↗

Few millimeter precision for baselines in the California Permanent GPS Geodetic Array

Geodetic measurements with Rogue GPS receivers from sites in the California Permanent GPS geodetic Array (PGGA) have been analyzed using the GIPSY orbit-determination and baseline-estimation software. Based on an unbiased selection of 23 daily measurements spanning 8 months, the LF contributions to the long-term repeatabilities of baseline measurements are approximately 5, 3, and 8 mm for the east, north, and vertical components. Short-term contributions to the long-term repeatabilities were evaluated by examining data from the week of October 21, 1990, which showed the lowest short-term scatter. For this week, daily repeatabilities of 2-3 mm in the horizontal and 4 mm in the vertical have been achieved for the 172-km JPL-Pinyon baseline, consistent with carrier phase date noise of about 6 mm. High quality (less than about 5 mm) repeatabilities have been achieved for all components of the other baselines as well.

Lindqwister, Ulf J.↗

Finite Element Contact Analysis and Redesign of Rotorcraft Planetary Gear Sets With Asymmetric Profiles

This article explores the use of asymmetric gear teeth for rotorcraft main rotor planetary gearsets. Two baseline designs having symmetric gear teeth were selected for redesign studies. Finite element-based contact analyses were used to compare designs. Bending stress predictions for the two existing baseline designs were compared to strain gage measurements to confirm the suitability of the modeling. The same modeling method is then used to assess design changes to improve the bending stress and contact pressure magnitudes using asymmetric tooth profiles. For the first redesign study, the selected gearset is mildly asymmetric, with a 4° difference in pressure angles between the two sides of a tooth. For the second redesign study, the selected gearset is strongly asymmetric with a 18° difference in pressure angles. The results demonstrate that the asymmetric tooth approach provides additional design flexibility toward balancing the contact stresses and bending stresses of the sun, planet, and ring members.

gear↗

A study of system requirements for Phobos/Deimos missions. Volume 4: Phase 3 results, combined missions to Mars and its satellites

Combined missions to Mars and Phobos/Deimos were considered in relation to large scientific returns at a low total cost. A matrix of all feasible major combined mission concepts was compiled. The most promising approach was selected from which a nominal mission profile was developed. A systems analysis was performed to trade off performance, configuration, and cost characteristics of candidate mission concepts. Configuration and subsystem optimization analysis were then conducted from which a baseline and an alternate program were selected. Program schedules and cost estimates were prepared for the recommended and alternate program.

Source record↗

Legume Crop Testing for Space

Long-duration missions beyond low-Earth orbit will encounter challenges in maintaining adequate nutrition and crew acceptability in the food system. In situ production of fresh produce can supplement nutrient deficiencies in the prepackaged diet. Currently, there are a relatively small number of crops that can be reliably grown for space crop production efforts. Recent challenges with Veggie plant growth technical demonstrations, such as interveinal chlorosis and necrosis of Tokyo Bekana Chinese cabbage when grown under elevated CO 2 (~3000 ppm) and narrow-band LED lighting, have highlighted the necessity to conduct rigorous ISS-relevant crop screening on the ground. Additionally, crops should be selected to address specific nutritional deficits, as identified by NASA’s Human Research Program, with an emphasis on having a diversity of crops to meet nutritional requirements and crew acceptability. To achieve this, the concept of Crop Readiness Level (CRL) has been developed to gauge readiness of crops for spaceflight applications. CRL determination includes assessing environmental compatibility, food safety considerations, relevant nutritional analysis, and sensory analysis. Recent testing at Kennedy Space Center has focused on advancing the CRL of a variety of legumes. Twenty-four varieties of peas ( Pisum sativum ) and beans ( Phaseolus vulgaris ) were grown under 300 μmol m -2 s -1 PPFD from LED lights, 3000 ppm CO2, and 23 °C to simulate an ISS environment. Crops were harvested and size and yield were assessed. Then, baseline nutritional analysis (Vitamins B1, C, K; elemental analysis; proximate analysis) and sensory evaluation were performed on eight down-selected varieties. These baseline tests will help in selecting candidate crops for future missions and assessing crop production hardware and changes in environmental conditions on future crop performance and nutritional quality.

LaShelle E Spencer↗

Development and RF Evaluation of a Four-Frequency Selective Surface Spacecraft Subreflector Antenna

NASA Jet Propulsion Laboratory has baselined a four frequency telecommunication system for the Cassini spacecraft antenna subsystems. This design required the design and development of a Frequency Selective Surface Subreflector (FSS) that is integrated into the High Gain Antenna Subsystem. This paper will discuss the development, mechanical and RF electrical testing of two alternate designs as flat panel prototypes that were conducted to verify the multifrequency design approach.

telecommunication system↗

Conformal Ablative Thermal Protection System for Planetary and Human Exploration Missions: An Update of the Technology Maturation Effort

This presentation will update the community on the development of conformal ablative TPS. As described at IPPW-10, in FY12, the CA-TPS element focused on establishing materials requirements based on MSL-type and COTS Low Earth orbit (LEO) conditions (q 250 Wcm2) to develop and deliver a conformal ablative TPS. This involved downselecting, manufacturing and testing two of the best candidate materials, demonstrating uniform infiltration of resins into baseline 2-cm thick carbon felt, selecting a primary conformal material formulation based on novel arc jet and basic material properties testing, developing and demonstrating instrumentation for felt-based materials and, based on the data, developing a low fidelity material response model so that the conformal ablator TPS thickness for missions could be established. In addition, the project began to develop Industry Partnerships. Since the nominal thickness of baseline carbon felts was only 2-cm, a partnership with a rayon felt developer was made in order to upgrade equipment, establish the processes required and attempt to manufacture 10-cm thick white goods. A partnership with a processing house was made to develop the methodology to carbonize large pieces of the white goods into 7.5-cm thick carbon felt.In FY13, more advanced testing and modeling of the downselected conformal material was performed. Material thermal properties tests and structural properties tests were performed. The first 3 and 4-point bend tests were performed on the conformal ablator as well as PICA for comparison and the conformal ablator had outstanding behavior compared to PICA. Arc jet testing was performed with instrumented samples of both the conformal ablator and standard PICA at heating rates ranging from 40 to 400 Wcm2 and shear as high as 600 Pa. The results from these tests showed a remarkable improvement in the thermal penetration through the conformal ablator when compared to PICAs response. The data from these tests were used to develop a mid-fidelity thermal response model. Additional arc jet testing in the same conditions on various seam designs were very successful in showing that the material could be joined with a minimum of adhesive and required no complicated gap and gap filler design for installation. In addition, the partnership with industry to manufacture thicker rayon felt was very successful. The vendor made a 2-m wide by 30-m long sample of 10-cm thick rayon felt. When carbonized, the resulting thickness was over 7.5-cm thick, nearly 4 times the thickest off-the-shelf carbon felt. In FY14, the project has initiated a partnership with another vendor to begin the scale-up manufacturing effort. This year, the vendor will duplicate the process and manufacture at the current scale for comparison with NASA-processed materials. Properties testing and arc jet testing will be performed on the vendor-processed materials. Planning for manufacturing large, 1-m x 1-m, panels will begin as well. In FY15, the vendor will then manufacture large panels and the project will build a 2-m x 2-m Manufacturing Demonstration Unit (MDU).

thermal protection systems↗